Land Size
An area of around 11.25 hectares is sufficient to accommodate the production plant and associated infrastructure. The potential to secure an additional 6 hectares exists to accommodate future expansion, particularly if/when the fertilizer plant option is exercised.
The plant will produce two essential animal feed supplement ingredients: Dicalcium Phosphate (DCP) and Monocalcium Phosphate (MCP). These Calcium Phosphate extracts constitute an essential supplementary additive in animal feeds adding the essential elements Phosphorous and Calcium, and can be chemically produced by using naturally occurring Phosphate Rock in a reaction with Sulphuric Acid.
Production Capacity
The proposed production facility is divided into three stages of development and the outputs are estimated as:
Stage 1 - 30,000 tonnes expected mid to late 2016
Stage 2 - 60,000 tonnes expected late 2017
Stage 3 - 90,000 tonnes or more subject to both local and export market demands
Raw Material Requirements for 30,000 Tonnes Output (Excluding By-Products)
Rock Phosphate - 45,000 tonnes delivered from Phosphate Hill or Mount Isa via rail
Sulphuric Acid - 30,000 tonnes delivered from Sun metals or from the Townsville Port via rail
Calcium Carbonate - 10,000 tonnes via road or rail
Calcium Hydroxide - 35,000 tonnes via road or rail
Utility Requirements
Water on Startup: Operational Consumption = 14 Cubic meters per hour
Water post Startup: Standard Operational Consumption = 7 Cubic meters per hour
Recycled Water = 7 Cubic meters per hour
Electricity = 160 Kilowatt hour
Natural Gas = 165 Cubic meters per hour
Input Material and Associated Output Material
| INPUT (Tonnes per Year) | OUTPUT (Tonnes) | ||
|---|---|---|---|
| Rock Phosphate | 45,000 | DCP | 30,000 Annually |
| Calcium Chloride (CaCl2) | 2,000 | Gypsum | 61,500 Annually |
| Calcium Carbonate (CaCO3) | 10,000 | Residue Cake | 16,500 Annually |
| Calcium Hydroxide (Ca(OH)2) | 35,000 | Off Gas | 1.05 per hour |
| Sulphuric Acid (H2SO4) | 30,000 | Vapour | 1.95 per hour |
Producing DCP from MCP has the advantages of:
- Producing pure Gypsum as a by-product
- High quality DCP with very low impurity content
- Less rock pretreatment required so no grinding or calcination (heating)
- Lower percentage of Rock Phosphate (P2O5) rock can be processed
- Better filterability due to reaction with a low concentration of Hydrochloric Acid (HCl)
- Lower operating temperature of the process
- Lower corrosion of plant and equipment due to the low HCl concentration and low temperature
- High overall yield of P2O5
Environmental Impact - Emissions & Consumption
Off Gas - Scrubbers and filters will remove any noxious and problematic emissions
Acid Vapour - The reaction of the dilute HCl on Rock Phosphate results in a relatively small vapour yield. However, this will be captured and returned to the process cycle.
Water - Waste water will be fully recycled for the production process.
Water Consumption - Rainwater tanks will be installed and water collected from the plant roofing (if it ever rains again around Charters Towers).
Plant Construction
Labour, building materials and plant equipment will be sourced locally wherever local and Australian products/personnel are available.